Apec 2002

Page 1
UNDERSTANDING AND CONTROLLING COMMON-MODE EMISSIONS IN HIGH-POWER ELECTRONICS
By Henry W. Ott
Henry Ott Consultants Livingston, NJ 07039 (973) 992-1793
www.hottconsultants.com
2001 Henry W. Ott
hott@ieee.org HOC
ELECTROMAGNETIC COMPATIBILITY
Page 2
THE BASIC PROBLEM

! Switching Power Supplies and Variable Speed Motor Drives Produce Large Noise Currents Which are Conducted Out to the Load, as Well as Conducted Back to The Power Source ! These Common-Mode Noise Currents are the Cause of: Low Frequency Conducted Emission, and High Frequency Radiated Emission ! Once One Has an Understanding of the Noise Source and Coupling Mechanism, a Solution Can be Determined ! Power Line Filters in Combination With Proper Load Side Filtering, Grounding, and/or Shielding Will Usually Solve Most Common-Mode Emission Problems.
2001 Henry W. Ott
HOC
Page 3
BASIC PRINCIPLE OF EMC
Return Current to its Source as Locally and Compactly as Possible
Minimize the Loop Area

HOC
2001 Henry W. Ott
Page 4
COMMON-MODE & DIFFERENTIAL MODE NOISE

! Differential-Mode Noise
Involves the Normal Operation of the Circuit Currents Flowing Around Loops Is Documented Schematics PCB Layout Wiring Diagrams Is Easy to Understand
! Common-Mode Noise
Does Not Relate to the Normal Operation of the Circuit Involves Parasitics Currents Flow Around Loops Usually Involving Parasitic Capacitance Is Not Documented Is More Difficult to Understand The Noise Source and Current Path Must First be Visualized and Understood Before a Solution Can be Determined
2001 Henry W. Ott
HOC
Page 5
RADIATION MECHANISMS
DIFFERENTIAL-MODE RADIATION
ted Radia on Emissi
COMMON-MODE RADIATION
Radiated Emission
PCB I/O Cable Icm
Signal PWB Gnd Plane Or Grid
I0
Ground
VN
Gnd Wire
E = K1 f2 A I0 E=K2 f L Icm
2001 Henry W. Ott
HOC
Page 6
BASIC ANTENNA TYPES
Antenna Type
Radiation Mechanism
Electromagnetic Field
Loop
Differential-Mode
Magnetic Field
Dipole
Common-Mode
Electric Field
2001 Henry W. Ott
HOC
Page 7
RADIATED VERSUS CONDUCTED C-M EMISSION

Radiation Directly Proportional to C-M Current
Product
ICM VCM ICM
Common-Mode Current Converted to a C-M Voltage by the Load or LISN Impedance
Common-Mode Noise Source
Parasitic Capacitance
Load or LISN
VCM
2001 Henry W. Ott
HOC
Page 8
EMC REGULATIONS PERTAINING TO C-M EMISSIONS
! North America (FCC/Industry Canada) ! European Union (EU) ! Military (MIL-STD)
2001 Henry W. Ott
HOC
Page 9
150 kHz 450 kHz
FREQUENCY RANGE
MIL-STD 461D, RE102 Radiated Emission 18 GHz
MIL-STD 461D, RE102 For Some Eq.
Military
MIL-STD 461D, CE102 Conducted Emission 10 kHz FCC Radiated Emission
Conducted
FCC Conducted Emission
40 GHz
Radiated
Commercial
EU ONLY
EU Radiated Emission
EU Conducted Emission
0.1 MHz
1 MHz
10 MHz
30 MHz
100 MHz
1,000 MHz
Frequency
2001 Henry W. Ott
HOC
Page 10
dBV 100
COMPARISON OF CONDUCTED EMISSION LIMITS

MIL-STD 461D, CE 102 Limit (115 V)
90
80
CISPR A Limit
70
FCC A Limit
60
CISPR B Limit
50
FCC B Limit
40 10 kHz 2001 Henry W. Ott 100 kHz 1 MHz Frequency 10 MHz
HOC
100 MHz
Page 11
HOW MUCH C-M CURRENT IS A PROBLEM

(Based on FCC Requirements)
Frequency <1.7 MHz * 1.7 - 30 MHz* 30MHz** 50 MHz** 100 MHz**
Class A 40 uA 120 uA 24 uA 15 uA 11uA
Class B 10 uA 10 uA 8 uA 5uA 3.5 uA
* Based on Conducted Emission Limits ** Based on Radiated Emission Limits
2001 Henry W. Ott
HOC
Page 12
THE BASIC C-M PROBLEM

Power Source Radiation Power Supply or Motor Drive Radiation Load
C-M Current Large dV/dt
C-M Current Switch
C-M Current
Ground * Any of the parasitic capacitance's could be a metallic connection to ground

2001 Henry W. Ott
HOC
Page 13
C-M CURRENT LOOPS

Power Source Power Supply or Motor Drive
Overall (Input-Output Loop)

Load
Large dV/dt
Switch
Input Loop
Output Loop
Ground
There Are Three Possible Loops to be Concerned With

2001 Henry W. Ott
HOC
Page 14
THE INVISIBLE SCHEMATIC

! Consists of: the dV/dt Generator, and the Parasitic Capacitance ! You Should be Able to Find and Visualize These Components ! Once the Invisible Schematic Components are Identified, the Required Control Techniques Become Fairly Straightforward and Obvious. They are not Black Magic.
2001 Henry W. Ott
HOC
Page 15
C-M EMISSION CONTROL TECHNIQUES

! Find a Way to: Reduce the Magnitude of the Source (dV/dt) Reduce the Parasitic Capacitance Reduce the C-M Current (e.g. Filtering) Return the C-M Current Through a Small Loop That Does Not Involve the External Ground Path (Small Loop Area) ! Usually The Closer You Can Get The Control to the Noise Source (the dV/dt Generator*) the More Effective the Technique
* Usually the Switching Transistors
2001 Henry W. Ott
HOC
Page 16
SWITCHING POWER SUPPLY CONDUCTED EMISSION, COMMON-MODE

Hot I DC Output
AC Input Neutral I I I Ground I Switching Transistor I I
C Heat Sink
50-500 pF Parasitic Capacitance
I = C-M Noise Current

1998 Henry W. Ott
HOC
Page 17
BASIC IGBT MOTOR DRIVE

IGBT Drive Circuit Motor or Inductive Load
Power Source
ICM
Motor Housing Usually Grounded
ICM
Ground
2001 Henry W. Ott
HOC
Page 18
BASIC SOLUTIONS TO THE C-M PROBLEM

! Minimize the dV/dt ! Reduce the Parasitic Capacitance ! Use Filtering To Reduce the C-M Current on the Cable ! Use Grounding To Return the C-M Current ! Use Shielding To Return the C-M Current To Reduce the Parasitic Capacitance
2001 Henry W. Ott
HOC
Page 19
BASIC IGBT MOTOR DRIVE

IGBT Drive Circuit Net C-M Cable Current Equal to I Motor
Power Source
I dV/dt
I
Ground
2001 Henry W. Ott
HOC
Page 20
THE BASIC IGBT MOTOR DRIVE PROBLEM (LOAD SIDE C-M CURRENT)
! The IGBT Switches are the C- M Voltage Source ! This Causes a Large Current (dI/dt) to Flow On the Output Leads to the Motor ! The Low Frequency Current Goes Through the Motor Windings as Intended ! The High Frequency Current, However, Capacitively Couples to The Motor Housing (Which is Usually Grounded) ! The Return Current Path Can Vary But Usually Flows Through the External Ground May Capacitively Couple Back to the IGBT Drive (As Shown in the Previous Slide) Or in Some Cases May Flow All the Way Back to the Power Source and From There Back to the Switches ! In All Cases, However, The Problem Arises Because of the Capacitance Between the Motor Windings and the Housing HOC
2001 Henry W. Ott
Page 21
POSSIBLE SOLUTIONS
! Power Input Side of the Switch Use a Power Line Filter ! Output (Load) Side of Switch Use Grounding or Shielding To Return C-M Current Without Using the External Ground Path Use Filtering To Return the C-M Current Locally to the Switch Reduce the dV/dt or the Motor Capacitance (Not Usually Practical) ! Remember the Switch is the Source of the C-M Voltage and the Motor Capacitance Provides the C-M Current Return Path
2001 Henry W. Ott
HOC
Page 22
GROUND WIRE FROM MOTOR HOUSING TO SWITCH COMMON Net C-M Cable Current
Equal to Zero Motor
Power Source
I Ground Wire (Routed With Output Conductor)
Ground This is the Ideal Solution But May Be Difficult to Implement Either the Motor Housing Must be Floating (as shown), or the Switch Common Must be Connected to Ground Alternative Approach: Add a Capacitor in Series With the Ground Wire to Provide an AC Connection Only Capacitor Value Limited by Leakage Current Requirements. Therefore, Not Very Effective at Low Frequencies
2001 Henry W. Ott
HOC
Page 23
SHIELDED CABLE SOLUTION

Net C-M Cable Current Equal to Zero Motor
Power Source I
Ground Similar to the Ground Wire Described Previously, But More Effective For Radiated Emission Shield Must Be Connected to Motor Housing on One End and to the Switch Common on the Other End Shield May Be Terminated With a Capacitor on One End as a Compromise
2001 Henry W. Ott
HOC
Page 24
CAPACITOR FILTER SOLUTION

Power Source
C1
I C2
Ground
Often Tried, However, it is a Good Way to Destroy the IGBTs You Are Dumping the Contents of a Large Capacitor (C1) Into a Smaller Capacitor (C2) Through a Low Impedance Switch With No Current Limiting
2001 Henry W. Ott
HOC
Page 25
L - C FILTER SOLUTION
L Power Source I
Ground
Often The Most Practical Solution, However, Beware of the Resonant Frequency of the Filter - Noise Will be Greater at this Frequency Inductive Kick of the Inductor Must be Snubbed, IGBT Diodes Will Normally Do This, You Could Also Use A C-M Choke in Place of the Inductor
2001 Henry W. Ott
HOC
Page 26
DAMPING FACTOR & FILTER RESONANCE
From: Ott, H. W., Noise Reduction Techniques in Electronic Systems, Second Edition, John Wiley, 1988
2001 Henry W. Ott
HOC
Page 27
TYPICAL FILTER COMPONENT VALUES

(L - C FILTER) Frequency 150 kHz 450 kHz 1 MHz 5 MHz 10 MHz 20 MHz 30 MHz Capacitor 1 uF 0.35 uF 0.16 uF 0.03 uF 0.015 uF 8000 pF 5000 pF Inductor 100 uH 35 uH 16 uH 3.2 uH 1.6 uH 0.8 uH 0.5 uH Resonant Freq. 16 kHz 45 kHz 100 kHz 513 kHz 1 MHz 2 MHz 3 MHz
2001 Henry W. Ott
HOC
Page 28
SWITCHING POWER SUPPLY NOISE SOURCES AND COUPLING PATHS

! The Most Common Noise Source is the Switching Transistor (Noise Will Be at Harmonics of the Switching Frequency, Normally Decreasing With Frequency -- Resonances May Cause Pop-Ups) ! Second is the Bridge Rectifier Noise (Noise Will Occur at Multiples of 120 Hz and is Differential-Mode) ! Third is Parasitic Oscillation (Usually Occurs at High Frequency and is Not Related to The Switching Frequency or 120 Hz) ! Fourth The Interactions Between the Power Supply & the Power Line Filter (The Power Supply Has a Negative Input Impedance at Power Line Frequencies and Can Oscillate if Terminated Improperly) ! Lastly, High Q Resonances & Other Miscellaneous Sources ! Parasitic Capacitance Provides the C-M Coupling Path Switching Transistor to Heat Sink Capacitance Primary to Secondary of Transformer Capacitance Reduce These Capacitances as Much as Possible
2001 Henry W. Ott
HOC
Page 29
POWER SUPPLY INPUT IMPEDANCE

! The Function of a Regulated Power Supply is to Keep the Output Voltage Constant ! If the Output Voltage is Constant, We Can Assume That the Output Current and Output Power Are Also Constant (Assuming a Fixed Load Impedance) ! If the Output Power is Constant, the Input Power Must Also be Constant ! Hence, the Input V x I Product Must be Constant ! If the Input Voltage Decreases, the Input Current Must Increase in Order to Maintain a Constant V x I Product ! Therefore, the Power Supply Has a Negative Input Impedance (The Input Impedance is Actually the Negative Reflected Load Impedance) ! And the Power Supply Can Become Unstable and Oscillate When The Power Line Filter is Added If the Power Line Filter Output Impedance is Not Low Enough
2001 Henry W. Ott
HOC
Page 30
SWITCHING POWER SUPPLY CONDUCTED EMISSION, COMMON-MODE

Hot I DC Output
AC Input Neutral I I I Ground I Switching Transistor I I
C Heat Sink
50-500 pF Parasitic Capacitance
I = C-M Noise Current

1998 Henry W. Ott
HOC
Page 31
COMMON MODE EQUIVALENT CIRCUIT OF SWITCHING POWER SUPPLY

Hot Switching Transistor LISN Neutral LISN Ground Heat Sink Parasitic Capacitance
1998 Henry W. Ott
HOC
Page 32
THE SWITCHING POWER SUPPLY PROBLEM
! Operating Voltage Level Within Power Supply = 150 V. ! Maximum Conducted Emission (Class B) = 250 uV. ! 250 uV / 150 V = 1.67 x 10-6 = -116 dB ! The Allowable Conducted Emission Level is One Millionth of the Operating Level ! Required Suppression = 120 dB
2001 Henry W. Ott
HOC
Page 33
TYPICAL POWER LINE FILTER
Power Line
X Cap. 0.1-1.0 F
Y Cap. 0.005 F Y Cap. 0.005 F
Power Supply
5-10 mH
Note: X Cap. Affects Differential-Mode Y Cap. Affects Common-Mode, The Series Combination Affects Differential-Mode Choke Affects Common-Mode, Leakage Inductance Affects Differential-Mode
1994 Henry W. Ott
HOC
Page 34
AC POWER LINE FILTERS
The Performance Of An AC Power Line Filter Is As Much A Function Of How And Where the Filter Is Mounted, And How The Leads Are Run To It, As It Is Of The Electrical Design Of The Filter.
2001 Henry W. Ott
HOC
Page 35
MINIMIZE PARASITICS
Minimize Power Line Filter Digital Logic Board
AC c Ground Controls Switching Power Supply Harmonics
Power Supply
DC
Controls Digital Logic Harmonics
2001 Henry W. Ott
HOC
Page 36
GENERATING COMMON-MODE NOISE BETWEEN THE INPUT & OUTPUT OF A SWITCHING POWER SUPPLY
DC Output Large dV/dt
Input Ground Conductor Power Switch ICM
ICM
2000 Henry W. Ott
HOC
Page 37
MEASURING THE COMMON-MODE CURRENT BETWEEN INPUT & OUTPUT A SWITCHING POWER SUPPLY
C
DC Output Large dV/dt
Input Ground Conductor Power Switch ICM
ICM
1 Ohm
V = ICM
2000 Henry W. Ott
HOC
Page 38
DEALING WITH COMON-MODE NOISE BETWEEN INPUT & OUTPUT OF A SWITCHING POWER SUPPLY
! Using an Isolated Converter in an Application Where the Input and Output Grounds are Tied Together at a Remote Point Can Often Cause a Problem ! Keep the Input and Output Circuits Isolated ! Connect Input and Output Grounds Together Internally With a Heavy Strap as Close to the Switching Element as Possible ! Add a Common-Mode Choke (Inductor, Ferrite, etc.) to the Input Circuit ! Reduce Transformer Inter-winding Capacitance ! Add a Faraday Shield to the Transformer ! Add a Choke to the DC Output Ground Lead
2000 Henry W. Ott
HOC
Page 39
MAGNETIC FIELD COUPLING TO OUTPUT WIRES
DC Output Wire Bundle Chassis
ICM
PCB
Area Into Which Magnetic Field Coupling Occurs
2000 Henry W. Ott
HOC
Page 40
THE CHASSIS WIRE CONCEPT
DC Output Wire Bundle Chassis
ICM
PCB
Area Into Which Magnetic Field Coupling Occurs Chassis Wire, Grounded at Both Ends
2000 Henry W. Ott
HOC
Page 41
CONDUCTED EMISSION TEST SET-UP

40 cm
Vertical Conducting Plane Bonded to Ground Plane
EUT
80 cm LISN
80 cm min. Floor Ground Plane
LISN Bonded to Ground Plane
1997 Henry W. Ott
HOC
Page 42
50 H LISN SPECIFIED BY THE FCC
L1 To Equipment Under Test 50 H C1 0.1 F To 50 Radio Noise Meter Or 50 Termination C2 1.0 F To AC Power Line
R1 1000
2000 Henry W. Ott
HOC
Page 43
TROUBLESHOOTING CONDUCTED EMISSION
! In Troubleshooting Conducted Emission it Would be Helpful if we Could Separate the CommonMode Current From the Differential-Mode Current ! This Would Allow Us to: Optimize the Power Line Filter Find the Cause of the Emission Within the Power Supply
2001 Henry W. Ott
HOC
Page 44
TOPOLOGY OF CONDUCTED EMISSION

LISN Phase
VP
50
CM
Gnd
VN
50
DM
CM
Power Supply
Neutral
VP = 50 (ICM + IDM)
VN = 50 (ICM - IDM)
2001 Henry W. Ott
HOC
Page 45
SEPARATING DIFFERENTIAL MODE AND COMMON MODE EMISSIONS

AC Power
VP
EUT
LISN
VN
Spectrum Analyzer
VCM = (VP + VN) / 2 Differential Mode or Common Mode Rejection Network VDM = (VP - VN) / 2
2001 Henry W. Ott
HOC
Page 46
SEPARATION OF COMMON MODE AND DIFFERENTIAL MODE NOISE VOLTAGES

Double Pole Switch 1:1
VP
DM
CM
LISN
VN
1:1
2VCM or 2VDM
From: Paul, C. R. & Hardin, K. B., Diagnosis and Reduction of Conducted Noise Emissions, 1988 IEEE International Symposium on EMC, Seattle Washington, August 2-4, 1988
2001 Henry W. Ott
HOC
Page 47
DIFFERENTIAL MODE REJECTION NETWORK

(LISN MATE)
16.7
VP
50 16.7 To Spectrum Analyzer or Receiver
LISN
VCM
VN
50
16.7
All Resistor Values +/- 0.1% From: Nave, M.J., Power Line Filter Design For Switched-Mode Power Supplies, Van Nostrand Rheinhold, 1991
2001 Henry W. Ott
HOC
Page 48
ALTERNATIVE METHOD OF SEPARATING C-M AND D-M CURRENTS USING A CURRENT PROBE
2IC
2ID
ID
Phase
IC
ID Neutral
Ground
IC
2IC
Note: When Measuring D-M Noise Current Be Careful That the Intentional Power Line Current Does Not Saturate the Core of the Current Probe
2001 Henry W. Ott
HOC
Page 49
SUMMARY
! Controlling C-M Emissions is Not Black Magic ! One Must, However, Be Able to Visualize the Noise Source and the Coupling Mechanism (The Invisible Schematic) The dV/dt Generator The Parasitic Capacitance The C-M Current Loop ! Once One Has an Understanding of the C-M Current Loop, the Required Control Techniques Become Fairly Straightforward and Obvious ! C-M Currents Must be Returned Locally and Compactly (Small Loop Area) ! Proper Use of Filtering, Grounding, and Shielding Will Solve Most C-M Emission Problems
2001 Henry W. Ott
HOC
Page 50
REFERENCES
! Ott, H. W., Noise Reduction Techniques in Electronic Systems, John Wiley, 1988 ! Nave, M. J., Power Line Filter Design for Switched-Mode Power Supplies, Van Nostrand Rheinhold, 1991 ! Fluke, J. C., Controlling Conducted Emissions by Design, Van Nostrand Rheinhold, 1991 ! Knurek, D. F., Reducing EMI in Switching Supplies, Powertechnics Magazine, August 1989 ! Paul, C. R. & Hardin, K. B., Diagnosis and Reduction of Conducted Noise Emissions, 1988 IEEE International Symposium on EMC, Seattle Washington, August 2-4, 1988
2001 Henry W. Ott
HOC

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Page 1

UNDERSTANDING AND CONTROLLING COMMON-MODE EMISSIONS IN HIGH-POWER ELECTRONICS

THE BASIC PROBLEM

2001 Henry W. Ott

BASIC PRINCIPLE OF EMC

Return Current to its Source as Locally and Compactly as Possible

Minimize the Loop Area

2001 Henry W. Ott

COMMON-MODE & DIFFERENTIAL MODE NOISE

2001 Henry W. Ott

PCB I/O Cable Icm

Signal PWB Gnd Plane Or Grid

BASIC ANTENNA TYPES

2001 Henry W. Ott

RADIATED VERSUS CONDUCTED C-M EMISSION

ICM VCM ICM

Common-Mode Current Converted to a C-M Voltage by the Load or LISN Impedance

Common-Mode Noise Source

2001 Henry W. Ott

EMC REGULATIONS PERTAINING TO C-M EMISSIONS

! North America (FCC/Industry Canada) ! European Union (EU) ! Military (MIL-STD)

2001 Henry W. Ott

MIL-STD 461D, RE102 For Some Eq.

MIL-STD 461D, CE102 Conducted Emission 10 kHz FCC Radiated Emission

COMPARISON OF CONDUCTED EMISSION LIMITS

40 10 kHz 2001 Henry W. Ott 100 kHz 1 MHz Frequency 10 MHz

HOW MUCH C-M CURRENT IS A PROBLEM

Frequency <1.7 MHz * 1.7 - 30 MHz* 30MHz** 50 MHz** 100 MHz**

Class A 40 uA 120 uA 24 uA 15 uA 11uA

Class B 10 uA 10 uA 8 uA 5uA 3.5 uA

* Based on Conducted Emission Limits ** Based on Radiated Emission Limits

2001 Henry W. Ott

THE BASIC C-M PROBLEM

C-M Current Large dV/dt

C-M Current Switch

Ground * Any of the parasitic capacitance's could be a metallic connection to ground

C-M CURRENT LOOPS

Overall (Input-Output Loop)

There Are Three Possible Loops to be Concerned With

THE INVISIBLE SCHEMATIC

2001 Henry W. Ott

C-M EMISSION CONTROL TECHNIQUES

2001 Henry W. Ott

SWITCHING POWER SUPPLY CONDUCTED EMISSION, COMMON-MODE

AC Input Neutral I I I Ground I Switching Transistor I I

50-500 pF Parasitic Capacitance

I = C-M Noise Current

BASIC IGBT MOTOR DRIVE

Motor Housing Usually Grounded

2001 Henry W. Ott

BASIC SOLUTIONS TO THE C-M PROBLEM

2001 Henry W. Ott

BASIC IGBT MOTOR DRIVE

2001 Henry W. Ott

2001 Henry W. Ott

I Ground Wire (Routed With Output Conductor)

SHIELDED CABLE SOLUTION

2001 Henry W. Ott

CAPACITOR FILTER SOLUTION

DAMPING FACTOR & FILTER RESONANCE

2001 Henry W. Ott

TYPICAL FILTER COMPONENT VALUES

2001 Henry W. Ott

Frequency <1.7 MHz * 1.7 - 30 MHz* 30MHz 50 MHz 100 MHz**